Inspection and Reliability Area Lead (AMIRAL project)
Saudi Aramco Total Refining And Petrochemical Company - Satorp
Total years of experience :16 years, 8 Months
Provide Engineering and Reliability advise to the currently most ambitious Petro Chemical project in the GCC: AMIRAL
Main activity: Complying with the Health, Safety and Environment (HSE) policies, perform and coordinate on-stream and Turnaround Inspection on the pressure containment equipment such as Heat Exchangers, Pressure Vessels (Columns and Drums), Pumps (Casings), Fired Pressure Vessels, Boilers & Fired Heaters, of the units of the Gas processing Plant - Shah Gas Field (Shah Gas Field, Abu Dhabi - UAE).
Develop, review and execute area inspection plans as a result of the RBI/FMECA analysis.
Develop, and review inspection input into plant equipment maintenance & Inspection plans for IDMS (inspection Data Management System - MERIDIUM).
Provide the turnaround scope of work for Inspection activities and upon completion, ensure continuing availability and integrity of plant and equipment.
Review and update the Plant Integrity Assurance System (linked with RBI system) with the latest inspection data.
Estimate corrosion rates, remaining life and next possible failure date (Using reliability data software - RELIASOFT) in order to inform stakeholders to plan for corrective maintenance of the related equipment.
Lead, motivate, develop and assess the assigned team, acting always as a coach to achieve business objectives and grow capability.
Develop technically sound and cost effective repairs / corrective maintenance, consistent with the company operating requirements, International codes / Engineering Practices and safety standards.
Make / Review the final report for each Fired and non fired Pressure Vessels, after the final boxup to specify the physical condition of the vessel before and after the maintenance / Turnaround.
Create the corrective Maintenance Recommendations reports indicating the repairs and procedures to follow, in order to preserve the mechanical integrity and reliability of the equipment. As well as following up on the implementation of the report.
Troubleshoot and investigate failures and potential failures and provide recommendations for repair / replacement based on result of Root-Cause Failure Analysis (RCFA)
Attending Multidisciplinary Business Units meetings and carry forward reliability improvement efforts.
Create the database & key indicators by failure mode to keep the record of failures of Heat Exchangers (on the assigned Units - Gas Sweetening & Condensate Stabilization, Amine Treating Unit, Sulfur Recovery Units, Condensate Hydroteating) in order to take reliability actions on the high-rate failure exchangers.
Main activity: Complying with the Health, Safety and Enviroment (HSE) policies, perform on-stream Inspection to the equipments such as Heat Exchangers, Pressure Vessels, Storage Tanks, Distillation Towers, service and Process Pipes, of the plants of Paraguaná Refining Complex - Cardón (CRP - Cardón).
Perform Quality Inspection to the maintenance repairs done to the equipments involved in the Refining Process, according with the codes and procedures of the corporation (PDVSA), API, ANSI, ASME, TEMA and many others.
Ensuring the reliability of the equipment repairs, supervising the repairs works and the materials used in a repair, in order to the equipment can operate both in normal and adverse conditions, and produce high quality gasoline and lube oils.
On the other hand, give recommendations to future maintenance in the Work Scopes.
Supervise NDE to verify if it complies with the Codes and procedures.
Reporting for each equipment, to specify the physical condition, making recommendations for future maintenance of such equipment
Create SAP notes indicating the repairs and procedures to follow. As well as following up on the implementation of the note.
Making AutoCad drawings of process lines, service lines to be include in Scope of Works and material list of it
Follow Risk Based Inspection (RBI) according to API-580/581, to Pressure Vessels, Heat Exchangers and Furnaces, in order to determine the operational reliability of the equipments above and propose parameters to be properly operated until the next Turnaround for maintenance.
Perform with the work team, the Failures Modes and Effects Analysis (FMEA) and the Root Cause Analysis (RCA), of the equipments in order to estimate it´s operational reliability and availability.
Troubleshoot and investigate failures and potential failures.
Attending Multidisciplinary business team meetings and carry forward reliability improvement efforts.
Identify “bad actor” equipments to get the causes of failure resolved.
Main projects where I was involved were:
- From 18th Ausgust 2011 to 25th August 2011: Corective Maintenance project of “DA-5 Tower of Furfural Extraction Unit”, in CRP - PDVSA (Centro Refinador Paraguaná) - CARDON”. I Inspected the Water separator Column and Drums associated to the Column.
- From 5th September 2011 until 20th October 2011: Inspection Team Lead of the Corrective Maintenance project of “C-1 Column of Fluid Catalytic Cracking Unit”. I Inspected the Fractionation Tower C-1, Stripper Tower C-2, Separator Tower C-3, Absorber Tower C-4 and the Furnance 58-F-1.
- From 1st November 2011 to 20th January 2012: Inspection Team Lead responsible of the planning and execution of the Making of the Scope of Work for the Maintenance project of Crude Distillation Unit #1 / Gas separator Unit #1 / Kerosene treater #2 in CRP - PDVSA (Centro Refinador Paraguaná) - CARDON year 2013”
- From 23th January 2012 to 30th March 2012: Inspection Team Lead responsible of the Inspection of pipes subject to CUI according to API 570. Making of Scope of Work for the repair of this pipes in the Lube Oil Plants, CRP - PDVSA (Centro Refinador Paraguaná) - CARDON.
- From 9th April 2012 to 10th November 2012: Inspection team lead responsible of the Inspection of Heat Exchangers, Furnances, Process pipes and also inspection of work in the Workshops of the Lube oil plants Expansion Project and Turnaround for repairs of the High Vacumm unit #1, Propane Deaphalting Unit #1 and #2, Furfural Extraction Unit and Mek Dewaxing Unit, CRP - PDVSA (Centro Refinador Paraguaná) - CARDON. Also I participated in the re-commissioning of the Unit.
- From 10th November 2012 to 9th August 2013: Inspection Coordinator Engineer of the DCU (Delay Coker Unit) and Platforming (wich includes CCR (Continuous Catalyst Regeneration)), responsible of on-stream inspections, in the Deep Conversion section in CRP - PDVSA (Centro Refinador Paraguaná) - CARDON.
Main activity: Gather the maintenance information of the conveyors belts, to introduce new designs and improvements in the construction of the new conveyors built by the Corporation
Gather the conveyor failure information of custumers to whom they provide Maintenance Service in order to plan the preventive maintenance and the corrective maintenance routine to each equipment/customer.
Make planning weekly, monthly and quarterly of the corrective maintenance services, which includes calculation of time and personnel required to optimize the human resource available.
Generate and deliver proposals for any kind of conveyors belt project in any of the industries in the territory (pharmaceutical, automotive, food & beverage).
Make weekly and monthly reports signed, reporting to the directors of the company the status of the works that it were planned.
Perform technical inspection to businesses that need conveyor systems, including the proposal of the ideal system: This, together with the design engineer to propose an efficient solution.
Establish continuous condition monitoring system at high-speed conveyors in order to ensure it´s reliability
Main activity: Estimate the friction lost of fluid pipes system like water, oil or gasoline, in order to provide the best technical support in the general pumping systems to help them achieve their goals such as reducing costs
Select appropriately the pump (monoblock or free shaft) using the flow and pressure variables, from the list of pump providers such as MALMEDI, KSB, PEDROLLO and others, that adjusts to the requirement of the client
Estimate and select the suitable pump on waste water systems specially for houses and buildings in general.
Estimate and select the suitable equipment (hydro - pneumatic or constant pressure) to supply water to a house, neighborhoods, hospitals and buildings in general, using a software.
Estimate and select the suitable fire fighting system to hospital, buildings in general and even refinery too, according to the NFPA (US) and COVENIN (Venezuela) rules
Make a budget of the equipment selected and send the budget to the respective customer, using a software called CISNES.
Main activity: Watch over the works made, and verify that were the works that it have been planning, obtaining the information of each foreman (civil, mechanic, welding, instrumentation), and ask they about the work in progress in order to avoid delay in the planning
Intersect the curve of real planning Vs. curve of the works done and estimate the rate of deviation if that were the case
Consider all of the variables to do an excellent initial planning in order to avoid deviations
Do with the Equipment Inspector, the “Inspection Notes” if needed, because some equipments may have additional work involving equipment and even personnel.
Make daily reports signed, reporting to the planning coordinator the status of the works in each equipment.
Main activity: Carry out the manual of Reliability Centered Maintenance (RCM) of envelopes machines from the reel of paper.
I carried out the Inspection Route of the machine, where I specified all parts of the machine.
Once ended the Inspection Route, I proceeded to perform the Failures Modes and Effects Analysis (FMEA) of machine parts according to their Criticality Analysis (CA), obtaining the necessary information from old maintenance data of the machine.
I Performed the Root - Cause Analysis (RCA) of the machine parts that had the higher failure rate per month and caused total stop of production.
Based in Total Productive Maintenance (TPM), I carried out the manual of Reliability Centerd Maintenance, in which I specified the maintenance activity for each part and for discipline (Mecahnical, Operational and Electric & Control) in order to optimize the cost of maintenance and increase the availability of the machine.
Fanally I proceeded to implement the new technique of maintenance in the machine, in order to reduce the stops of the machine, the cost of operation and increase the daily production.
Training in Reliability KPI's, Reliability Centered Maintenance (RCM), RCA development, Leaership, Management of Change in organizations, Finance and costs, among other important subjects